Flame-retardant resin composition

ABSTRACT

A composite metal hydroxide is provided for use as a flame-retardant in a resin or rubber composition. The composite metal hydroxide is a solid solution having the formula (1) Ca 1-x  M 2+  x(OH) 2 . M is at least one member selected from the group consisting of Mg, Mn, Fe, Co, Ni, Cu and Zn and x is in the range of 0.001≦x&lt;0.995. Two preferred composite metal hydroxides have the formula (2) Ca 1-x  Mg 2+  x(OH) 2  wherein x is in the range of 0.001≦x&lt;0.995 and the formula (3) Ca 1-x  (Mg, Ni, Mn) x  (OH) 2  wherein x is in the range of 0.001≦x&lt;0.995.

This is a divisional application of Ser. No. 08/173,064, filed Dec. 27,1993 now U.S. Pat. No. 5,422,092.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a flame retardant and a flame-retardantresin and/or rubber composition containing said flame retardant. Morespecifically, it relates to a flame retardant which exhibits excellentflame retardancy when incorporated into a resin or rubber and aflame-retardant resin and/or composition containing said flameretardant.

2. Description of Related Art

The requirement of flame retardancy for a resin and rubber (to be simplyreferred to as "resin" hereinafter) is getting more stringent year afteryear. For satisfying this requirement, there is conventionally employeda method in which a so-called halogen-containing flame retardant,typified by a combination of an organic halide and antimony trioxide, isincorporated into a resin. However, the following problems of ahalogen-containing flame retardant have come to be recognized. It isliable to generate halogen gas during the processing, and it,corrodes anapparatus, etc. When combusted, it generates a large amount of toxicsmoke to threaten human life, and it corrodes peripheral equipment toterminate the function of the equipment.

Aluminum hydroxide and magnesium hydroxide contain no halogen and arefree from the above problems. These hydroxides are attracting attention,and the consumption thereof is increasing year after year. Since,however, aluminum hydroxide starts dehydration at about 190° C., itmakes almost all resins foam in processing, and deteriorates theirproduct value, The temperature for the processing Is therefore requiredto be lower than the above temperature, and the resins to which aluminumhydroxide can be incorporated are limited in kind.

Magnesium hydroxide starts dehydration around 340° C., and it cantherefore be used with almost all resins without the foaming problem.Further, the present inventor and some other coinventors have invented amagnesium hydroxide suitable as a flame retardant and a process for theproduction thereof. Magnesium hydroxide is thus beginning to be amainstream in the field of halogen-free flame retardants. However, forimparting a resin with sufficient flame retardancy, magnesium hydroxideis required to be used in a large amount as well as aluminum hydroxide.For example, the amount of magnesium hydroxide required per 100 parts byweight of a resin is about 150 parts by weight or more. Further,magnesium hydroxide is relatively expensive, and it hence increases thecost much more than a halogen-containing flame retardant. The use ofmagnesium hydroxide which is a safe flame retardant is not necessarilysatisfactorily expanding.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a flame retardanthaving excellent flame retardancy, which can overcome the problems ofmagnesium hydroxide in its relatively high price and the requirement ofa large amount for imparting a resin with sufficient flame retardancy,and which can be produced at a relatively low cost.

It is another object of the present invention to provide a flameretardant which can be produced at a relatively low cost and hasexcellent flame retardancy.

It is still another object of the present invention to provide aflame-retardant resin composition containing said flame retardant.

According to the present invention, the above objects and advantages ofthe present invention are achieved, first, by a composite metalhydroxide of the formula (1) which is a solid solution and is for use asa flame retardant for a resin or rubber,

    Ca.sub.1-x M.sup.2+.sub.x (OH).sub.2                       ( 1)

wherein M is at least on e member selected from the group consisting ofMg, Mn, Fe, Co, Ni, Cu and Zn and x is in the range of 0.001≦x<0.995,preferably 0.005≦x<0.99, more preferably 0.01≦x≦0.7, particularlypreferably 0.04≦x<0.5.

Further, according to the present invention, the above objects andadvantages of the present invention are achieved, second, by a compositemetal hydroxide of the formula (2) for use as a flame retardant for aresin or rubber,

    Ca.sub.1-x Mg.sup.2+.sub.x (OH).sub.2                      ( 2)

wherein x is is in the range of 0.001≦x<0.995, preferably 0.005≦x<0.99,more preferably 0.01≦x≦0.7, particularly preferably 0.04≦x<0.5, whichcomposite metal hydroxide is at least one of a calcium hydroxide-basedsolid solution, a mixture of a calcium hydroxide-based solid solutionwith a magnesium hydroxide-based solid solution and a magnesiumhydroxide-based solid solution.

Further, according to the present invention, the above objects andadvantages of the present invention are achieved, third, by a compositemetal hydroxide of the formula (3) for use as a flame retardant for aresin or rubber,

    Ca.sub.1-x (Mg, Ni, Mn).sub.x (OH).sub.2                   ( 3)

wherein x is is in the range of 0.001≦x<0.995, preferably 0.005≦x<0.99,more preferably 0.01≦x≦0.7, particularly preferably 0.04≦x<0.5, whichcomposite metal hydroxide necessarily contains Ni and/or Mn and is atleast one of a calcium hydroxide-based solid solution, a mixture of acalcium hydroxide-based solid solution with a magnesium hydroxide-basedsolid solution and a magnesium hydroxide-based solid solution.

Further, according to the present invention, there is provided aflame-retardant resin and/or rubber composition containing 100 parts byweight of a resin and/or a rubber and 20 to 250 parts by weight of thecomposite metal hydroxide of the above formula (1).

DETAILED DESCRIPTION OF THE INVENTION

The present inventor has focused on calcium hydroxide as a flameretardant which can overcome the price problem of magnesium hydroxideused as a flame retardant. Calcium hydroxide is very cheap, there is anabundant supply of its source and it is safe to a human body. However,calcium hydroxide has a dehydration temperature of about 540° C., andthis hydration temperature is much higher than decompositiontemperatures of resins and rubbers. As a result, the flame retardancy ofcalcium hydroxide is very poor, and further, its acid resistance is alsovery poor. For example, calcium hydroxide has a problem in that itgradually reacts with carbon dioxide gas in air to form calciumcarbonate or it is dissolved in water with pH of 12 or less. Therefore,calcium hydroxide has never been considered useful as a flame retardant.

It has been found that the calcium hydroxide solid solution of theformula (3) invented by the present inventor (Japanese PatentApplication No. 319827/1991) surprisingly overcomes the above problemsof calcium hydroxide and shows improved flame retardancy and acidresistance.

    Ca.sub.1-x M.sub.1.sup.2+.sub.x (OH).sub.2                 ( 4)

wherein M₁ is at least one member selected from the group consisting ofMg, Mn, Fe, Co, Ni, Cu and Zn, and x is in the range of 0.005≦x<0.4.

Further, when M₁ in the formula (4) is magnesium and when x in theformula (4) is 0.4 or more, i.e., exceeds the range in which a calciumhydroxide solid solution alone is formed, "magnesium hydroxide" isformed in addition to the calcium hydroxide solid solution. It has beenfound that the so-formed "magnesium hydroxide" is a solid solution ofcalcium hydroxide in magnesium hydroxide. It is expected that thedehydration and decomposition temperature of the above magnesiumhydroxide solid solution is higher than the dehydration anddecomposition temperature, about 420° C., of magnesium hydroxide.However, it has been surprisingly found that the dehydration anddecomposition temperature of the above magnesium hydroxide solidsolution is lower than that of magnesium hydroxide by about 60° C. inthe maximum value.

It has been further found that a mixture system of the calciumhydroxide-based solid solution and the magnesium hydroxide-based solidsolution exhibits flame retardancy equal to or higher-than that ofmagnesium hydroxide. The reason therefor is not clear, while the flameretardancy is considered to be improved for the following reasons.

The calcium hydroxide-solid solution is dehydrated/decomposed at atemperature lower than the dehydration and decomposition temperature ofcalcium hydroxide by approximately 40° to 50° C. The magnesiumhydroxide-based solid solution is dehydrated/decomposed at a temperaturelower than the dehydration and decomposition temperature of magnesiumhydroxide by about 60° C. in the maximum value. The dehydrationtemperatures of the calcium hydroxide-based solid solution and themagnesium hydroxide-based solid solution are nearer to the ignitiontemperatures of a resin and a rubber than the dehydration temperaturesof calcium hydroxide and magnesium hydroxide are, and the heat generatedby a resin and a rubber can be effectively absorbed. The flame retardantwhich is the composite metal hydroxide of the formula (1) or the solidsolution of the formula (2) has excellent flame retardancy over calciumhydroxide, but also, when it contains magnesium, has excellent flameretardancy over magnesium hydroxide in some cases.

The flame retardant of the present invention has another advantage inthat it is formed mainly from a less expensive and abundant raw materialand can be produced by a relatively facile method. That is, calciumhydroxide itself easily undergoes crystal growth, and a larger size ofthe crystal is suitable as a flame retardant. The flame retardant of thepresent invention shows improved acid resistance over calcium hydroxide,since M(OH)₂ contained in the calcium hydroxide-based solid solution hasexcellent acid resistance over calcium hydroxide. In particular, thistendency remarkably appears when the calcium hydroxide-based solidsolution contains nickel hydroxide.

The composite metal hydroxide of the formula (1) is a solid solutionformed of calcium hydroxide and M(OH)₂, a mixture of said solid solutionwith a magnesium hydroxide-based solid solution, or a solid solutionformed of magnesium hydroxide, Ca and M(OH)₂. When the composite metalhydroxide consists of the calcium hydroxide-based solid solution, orwhen it is consists of magnesium hydroxide-based solid solution, thediffraction angle in X-ray powder diffraction pattern varies to a slightextent depending upon the ionic radius and content of M, while the X-raydiffraction pattern is substantially the same as that of calciumhydroxide or magnesium hydroxide. When the composite metal hydroxideconsists of both the calcium hydroxide-based solid solution and themagnesium hydroxide-based solid solution, the diffraction anglesimilarly varies to a slight extent depending upon the ionic radius andcontent of M(OH)₂, while the diffraction pattern is substantially thesame as those of calcium hydroxide and magnesium hydroxide. When thecomposite metal hydroxide consists of the calcium hydroxide-based solidsolution, the differential thermal analysis (DTA) thereof shows oneendothermic peak, and the peak is lower than the peak, 536° C., ofcalcium hydroxide by approximately 40° to 50° C. in the maximum value.When the composite metal hydroxide consists of the calciumhydroxide-based solid solution and the magnesium hydroxide-based solidsolution, DTA shows two endothermic peaks corresponding to those ofcalcium hydroxide and magnesium hydroxide, and the peaks shift towardlower temperatures respectively as compared with the peaks of calciumhydroxide and magnesium hydroxide.

When the composite metal hydroxide consists of the calciumhydroxide-based solid solution and either M(OH)₂ other than magnesiumhydroxide or a solid solution of M(OH)₂ with Ca(OH)₂ other thanmagnesium hydroxide, DTA shows two endothermic peaks. In this case, theendothermic peak corresponding to that of M(OH)₂ overlaps the processingtemperature of a resin or a rubber, and foaming may occur. In somecases, therefore, the co-presence of a solid solution of M(OH)₂ otherthan magnesium hydroxide is not preferred. The co-presence of thecalcium hydroxide-based solid solution and the magnesium hydroxide-basedsolid solution causes no foaming at processing temperatures of almostall resins and rubbers. With an increase in the content of the magnesiumhydroxide-based solid solution, the flame retardancy tends to beimproved. However, when x exceeds about 0.7, the crystal growth of thecalcium hydroxide-based solid solution tends to be prevented to someextent.

In the composite metal hydroxide of the present invention, the size ofthe crystal is preferably 0.2 to 4 μm, more preferably 0.4 to 2 μm, andthe composite metal hydroxide is preferably almost free of secondaryaggregation or the degree of secondary aggregation is quite low. In thisconnection, the size of secondary particles is preferably almost thesame as the size of the crystal. The BET specific surface area of thecomposite metal hydroxide of the present invention is preferably 1 to 20m² /g, more preferably 3 to 10 m² /g. The above properties are requiredto be in the above ranges for obtaining a resin and/or rubbercomposition which is excellent in processability, appearance, mechanicalstrength and flame retardancy.

The composite metal hydroxide of the present invention may be useddirectly as a flame retardant, or before use, it may be surface-treatedwith at least one member selected from the group consisting of higherfatty acid, an anionic surfactant, phosphate ester, a coupling agent(silane-, titanate- or aluminum-containing coupling agent), a polyhydricalcohol and fatty acid ester.

The surface-treating agent preferably includes higher fatty acids havingat least 10 carbon atoms such as stearic acid, erucic acid, palmiticacid, lauric acid and behenic acid; alkali metal salts of the abovehigher fatty acids; sulfates of higher alcohols such as stearyl alcoholand oleyl alcohol; anionic surfactants such as sulfates of polyethyleneglycol ether, amidated sulfate, ester-bonded sulfate, ester-bondedsulfonate, amidated sulfonate, ether-bonded sulfonate, ether-bondedalkylallylsulfonate, ester-bonded alkylallylsulfonate and amidatedalkylallylsulfonate; phosphate esters such as monoester or diester oforhtophosphoric acid and oleyl alcohol or stearyl alcohol, a mixture ofthese esters, and acid-form esters, metal salts or amine salts of theseesters; silane-containing coupling agents such as vinyl ethoxysilane,vinyl triethoxysilane, vinyltris(2-methoxyethoxy)silane,gamma-methacryloxypropyltrimethoxysilane,gamma-aminopropyltrimethoxysilane,beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane,gamma-glycidoxypropyltrimethoxysilane andgamma-mercaptopropyltrimethoxysilane; titanate-containing coupling agenssuch as isopropyltriisostearoyl titanate,isopropyltris(dioctylpyrophosphate)titanate,isopropyltri(N-aminoethylaminomethyl)titanate andisopropyltridecylbeznenesulfonyl titanate; aluminum-containing couplingagents such as acetoalkoxyaluminum diisopropylate and esters ofpolyhydric alcohol and fatty acid such as glycerin monostearate andglycerin monooleate.

The composite metal hydroxide of the present invention can be surfacetreated by a wet or dry method known per se. For example, the wet methodmay be carried out by the above surface treating agent in the form of aliquid or an emulsion is added to a slurry of the composite metalhydroxide and the mixture is mechanically fully stirred at a temperatureup to about 100° C. The dry method may be carried out by adding thesurface treating agent in the form of a liquid, an emulsion or a solidto the composite metal hydroxide while a powder of the composite metalhydroxide is fully stirred with a mixer such as a Henschel mixer andfully stirring the mixture under heat or no heat. The amount of thesurface treating agent is properly determined as required, while theamount thereof based on the weight of the composite metal hydroxide ispreferably approximately 0.1 to 10% by weight. After the heat treatment,the composite metal hydroxide is, for example, properly washed withwater, filtered, granulated, dried, milled and classified to obtain afinal product.

For producing the composite metal hydroxide of the present invention,various methods can be employed. For example, it can be produced by aco-precipitation method in which an aqueous solution containing calciumion and M ion is prepared and an alkali in an amount nearly equal inkthe total equivalent of the calcium and M is added to the aqueoussolution with stirring to precipitate a composite metal hydroxide.Further, it can be produced by a method in which a solid solution ofcalcium oxide and MO is subjected to a hydration reaction. It can bealso produced by another method in which a slurry containing calciumoxide and/or calcium hydroxide and an aqueous solution containing M ionare mixed and allowed to react. Further, it can be also produced by asol-gel method in which alcoholates of calcium and M is hydrolyzed. Forpromoting further crystal growth and decreasing secondary aggregation,the composite metal hydroxide obtained by any one of the above method ispreferably hydrothermally treated in an autoclave at approximately 110°to 250° C. for about 1 hour while reaction mother liquor is co-presentor after a salt such as CaCl₂, CaBr₂, NH₄ Cl, NaCl or KCl is added as acrystal growth promoter.

The source for calcium for forming the composite metal hydroxideincludes calcium oxide (quick lime), calcium hydroxide (slaked lime),calcium chloride, calcium nitrate, calcium bromide, calcium iodide,calcium acetate and alcoholates such as calcium ethoxide and calciumpropoxide. The source for M ion includes chlorides, bromides, iodides,fluorides, nitrates, formates and alcholates such as propioxides,ethoxides, propoxides and isopropoxides of divalent metals such as Mg²⁺,Mn²⁺, Fe²⁺, Co²⁺, Ni²⁺, Cu²⁺ and Zn²⁺, bittern, seawater and undergroundbrine.

The alkali used for forming the composite metal hydroxide includescalcium hydroxide, calcium oxide, sodium hydroxide and potassiumhydroxide.

The resin and rubber used in the present invention includesthermoplastic resins such as a copolymer of vinyl chloride and ethylene,propylene or vinyl acetate, a copolymer of chlorinated polyethylene,polyethylene or ethylene and other alpha-olefin, a copolymer of ethyleneand vinyl acetate, ethyl acrylate or methyl acrylate, polypropylene, acopolymer of propylene and other alpha-olefin, polybutene-1,polystyrene, a copolymer of styrene and acrylronitrile, a copolymer ofethylene and hexene or octene, polyacrylate, polymethacrylate,polyurethane, polyether, polyester and polyamide, thermosetting resinssuch as a phenolic resin, a melamine resin, an epoxy resin, anunsaturated polyester resin an alkyd resin, EPDM, SBR, NBR, butylrubber, chloprene rubber, isoprene rubber, chlorosulfonated andpolyethylene.

In the resin and/or rubber composition of the present invention, theamount of the composite metal hydroxide is properly selected dependingupon the kind of the resin and/or rubber and the kind of the compositemetal hydroxide, while the amount of the surface-treated orsurface-untreated composite metal hydroxide per 100 parts by weight ofthe resin and/or rubber is approximately 20 to 250 parts by weight,preferably approximately 50 to 200 parts by weight. When the amount ofthe composite metal hydroxide is smaller than the above lower limit, theflame retardancy is insufficient. When the above amount exceeds theabove upper limit, for example, there may be disadvantages that thetensile strength and Izod impact strength decrease, or that the acidresistance deteriorates.

The resin and/or rubber and the composite metal hydroxide can be mixedand kneaded by any means by which these components can be homogeneouslymixed. For example, a single-screw extruder, a twin-screw extruder, aroll or a Banbury mixer may be employed. The resin and/or rubbercomposition can be molded by any molding method know per se dependingupon the kind of the resin and/or rubber and the kind of an intendedmolded article. For example, it can be molded by any one of an injectionmolding method, an extrusion molding method, a blow molding method, apress forming method, a rotary molding method, a calender moldingmethod, a sheet forming method, a transfer molding method, laminateforming method and a vacuum molding method.

The resin and/or rubber composition of the present invention may containat least one of various additives as required in addition to thecomposite metal hydroxide of the present invention. These additives areflame retardant aids such as a carbon powder, ferrocene, anthracene,polyacetylene, red phosphorus, an acrylic fiber, nickel oxide, fibrousmagnesium hydroxide and fibrous composite metal hydroxide of the formulaMg_(1-x) M₃ ²⁺ _(x) (OH)₂ in which M₃ is at least one member selectedfrom Mn, Fe, Co, Ni, Cu and Zn and x is a number in the range of0.005<x<0.5 (Japanese Patent Application No. 162203/1991). The amount ofthe above flame retardant aid per 100 parts by weight of the resinand/or rubber is preferably approximately 0.01 to 10 parts by weight.Further, other additive may be incorporated as a lubricant and animprover for water resistance and acid resistance (resistance towhitening). These additives include zinc behenate, magnesium behenate,zinc stearate, calcium stearate, magnesium stearate, zinc stearate andaluminum stearate. The amount of the above "other additive" per 100parts by weight of the resin and/or rubber is preferably approximately0.1 to 10 parts by weight.

In addition to the above additives, the flame retardant resincomposition of the present invention may contain other additives such asan antioxidant, an ultraviolet shielding agent, an antistatic agent, apigment, an antifoamer, a plasticizer, a filler, a reinforcing agent, anorganic halogen flame retardant and a crosslinking agent.

As specified above, the present invention provides a flame retardantwhich is less expensive and is excellent in flame retardancy and aflame-retardant resin and/or rubber composition containing said flameretardant.

The present invention will be detailed hereinafter with reference toExamples.

EXAMPLE 1

20 Liters of a Ca(OH)₂ slurry prepared by slaking quick lime and sievingthe slaked lime through a 200-mesh sieve was placed in a 50-literreactor, and while the slurry was stirred around 70° C., 3.2 liters ofan aqueous solution containing 1.0 mol/l of magnesium chloride was addedand reacted with the slurry. The reaction mixture was placed in anautoclave, and treated at 120° C. for 2 hours. Then, the reactionproduct (composite metal hydroxide) was recovered by filtration, washedwith water and dispersed in water. The dispersion was heated up to 70°C., and an aqueous solution (about 70° C.) of pre-dissolved sodiumoleate was added with stirring, to surface-treat the reaction product.The amount of the sodium oleate based on the weight of the resultingproduct was 2% by weight. Then, the surface-treated composite metalhydroxide was recovered by filtration, washed with water, dehydrated,granulated and dried. Separately, part of the slurry before the surfacetreatment was taken, dehydrated and dried, and the remainder wasmeasured for a composition by a chelatometric titration method, for acrystal structure by X-ray diffractometry, and for a BET specificsurface area by a liquid nitrogen adsorption method. Further, the sameremainder as above was ultrasonically dispersed in ethyl alcohol as adispersing medium for about 5 minutes and measured for an averagesecondary particle diameter by a microtrack method. Table 1 shows theresults.

100 Parts by weight of impact-resistant polypropylene, 0.2 part byweight of an antioxidant (0.1 part by weight of Irganox 1010 and 0.1part by weight of Weston 626) and the composite metal hydroxide in anamount shown in Table 1 were uniformly mixed, and the mixture waskneaded with a twin-screw extruder at about 230° C. to obtain compositepellets. The pellets were dried with a vacuum dryer at 120° C. for 2hours, and then injection molded at about 230° C. to obtain test pieces.The test pieces were evaluated for flammability, mechanical strength andappearance. Table 1 shows the results. For the evaluation of theflammability, the test piece having a thickness of 1/8 inch wasevaluated according to UL-94. The above-obtained composite metalhydroxide had the following chemical composition.

    Ca.sub.0.91 Mg.sub.0.09 (OH).sub.2

EXAMPLES 2 and 3

Example 1 was repeated except that the aqueous solution containing 1.0mol/l of magnesium chloride was replaced with an aqueous solutioncontaining 2.0 mol/l of magnesium chloride, that the amount of theaqueous solution was changed to 7.0 liters (Example 2) or 12.0 liters(Example 3), and that the temperature for hydrothermally treating thereaction product was changed to 170° C. Table 1 shows the results. Theabove-obtained composite metal hydroxide had the following chemicalcomposition.

    Ca.sub.0.64 Mg.sub.0.36 (OH).sub.2                         Example 2

    Ca.sub.0.40 Mg.sub.0.60 (OH).sub.2                         Example 3

EXAMPLE 4

A composite metal hydroxide was obtained in the same manner as inExample 1 except that the aqueous solution containing 1.0 mol/l ofmagnesium chloride was replaced with 3.2 liters of a zinc nitrate/nickelnitrate mixed aqueous solution (Zn²⁺ =0.75 mol/l, Ni²⁺ =0.25 mol/l, 30°C.). The so-obtained composite metal hydroxide was placed in anautoclave, hydrothermally treated at 170° C. for 2 hours, recovered byfiltration, washed with water, dried and milled. The composite metalhydroxide was surface-treated with 1% by weight ofgamma-aminopropyltrimethoxysilane. Test pieces were prepared, andevaluated, in the same manner as in Example 1. Table 1 shows theresults. The above-obtained composite metal hydroxide had the followingchemical composition.

    Ca.sub.0.92 Zn.sub.0.06 Ni.sub.0.02 (OH).sub.2

EXAMPLE 5

A composite metal hydroxide was obtained in the same manner as inExample 1 except that the aqueous solution containing 1.0 mol/l ofmagnesium chloride was replaced with 8.0 liters of a cupricnitrate/nickel nitrate mixed aqueous solution (Cu²⁺ =0.75 mol/l, Ni²⁺=0.25 mol/l, 30° C.). The so-obtained composite metal hydroxide wastreated in the same manner as in Example 4. Test pieces were prepared,and evaluated, in the same manner as in Example 1. Table 1 shows theresults. The above-obtained composite metal hydroxide had the followingchemical composition.

    Ca.sub.0.80 Cu.sub.0.15 Ni.sub.0.05 (OH).sub.2

EXAMPLE 6

10 Liters of a magnesium chloride/calcium chloride mixed aqueoussolution (Mg²⁺ =2.0 mol/l, Ca²⁺ =1.0 mol/l, 30° C.) was placed in a25-liter reactor, and while the mixed aqueous solution was stirred, 11liters of a slurry containing 2 mol/l of slaked lime (20° C.) was addedand allowed to react with the aqueous solution. The reaction mixture wasplaced in an autoclave and hydrothermally treated at 180° C. for 4hours. The reaction product was recovered by filtration, washed withwater and dispersed in water. Thereafter, the reaction product wastreated in the same manner as in Example 1, and test pieces wereprepared and evaluated in the same manner as in Example 1. Table 1 showsthe results. The above-obtained composite metal hydroxide had thefollowing chemical composition.

    Ca.sub.0.02 Mg.sub.0.98 (OH).sub.2

EXAMPLE 7

12 Liters of a calcium chloride/manganese chloride/nickel chloride mixedaqueous solution (Ca²⁺ =2.0 mol/l, Mn²⁺ 0.1 mol/l, Ni²⁺ =0.05 mol/l, 30°C.) from which oxygen had been removed by blowing in nitrogen gas and 12liters of an aqueous solution containing 4 mol/l of NaOH from whichoxygen had been removed by blowing in nitrogen gas were charged into a25-liter reactor containing 1 liter of oxygen-free water at a flowingrate of 200 ml/minute, respectively, with a quantitative pump, and theresultant mixture was allowed to react with stirring. Then, the reactionmixture was placed in an autoclave, and hydrothermally treated at 180°C. for 2 hours. The reaction product was recovered by filtration, washedwith water and dispersed in water and surface-treated with 1% by weight,as a solid, of lauroyl sarcosine at about 60° C. with stirring. Then,the surface-treated product (composite metal hydroxide) was recovered byfiltration, washed with water and dried. The above procedures were allcarried out under nitrogen gas atmosphere. The above-obtained compositemetal hydroxide in an amount shown in Table 2 was mixed with 100 partsby weight of nylon 6 shown in Table 2 and test pieces were prepared fromthis mixture, and evaluated, in the same manner as in Example 1. Table 2shows the results. The composite metal hydroxide had the followingchemical composition.

    Ca.sub.0.85 Mn.sub.0.10 Ni.sub.0.05 (OH).sub.2

EXAMPLE 8

Test pieces were prepared in the same manner as in Example 7 except thatthe mixed aqueous solution was replaced with 12 liters of a calciumchloride/magnesium chloride/nickel chloride mixed aqueous solution (Ca²⁺=2.0 mol/l, Mg²⁺ =0.8 , Ni²⁺ =0.09 mol/l, 40° C.). The test pieces wereevaluated in the same manner as in Example 7. Table 2 shows the results.The composite metal hydroxide had the following chemical composition.

    Ca.sub.0.55 Mg.sub.0.40 Ni.sub.0.05 (OH).sub.2

Comparative Example 1

Test pieces were prepared in the same manner as in Example 1 except thatthe aqueous solution containing magnesium chloride was replaced with 7.2liters of an aqueous solution containing 1.0 mol/l of nickel chloride.The test pieces were evaluated in the same manner as in Example 1. Table1 shows the results. The so-obtained compound had the following chemicalcomposition.

    Ca.sub.0.80 Ni.sub.0.20 (OH).sub.2

Comparative Example 2

The same slurry of calcium hydroxide as that used in Example 1 wassurface-treated in the same manner as in Example 1, and test pieces wereprepared, and evaluated, in the same manner as in Example 1. Table 1shows the results. The calcium hydroxide had the chemical composition ofCa(OH)₂.

Comparative Example 3

Test pieces were prepared in the same manner as in Example 1 except thatthe composite metal hydroxide was replaced with commercially availablemagnesium hydroxide (surface-treated with 2% by weight of sodium oleate)for use as a flame retardant. The test pieces were evaluated in the samemanner as in Example 1. Table 1 shows the results. The above magnesiumhydroxide had the chemical composition of Mg(OH)₂.

Referential Example 1

Table 1 shows the physical properties of polypropylene containing noflame retardant.

Referential Example 2

Table 2 shows the physical properties of nylon 6 containing no flameretardant.

EXAMPLE 9

A composite metal hydroxide was prepared in the same manner as inExample 2 except that the amount of the aqueous solution containing 2.0mol/l of magnesium chloride was changed to 8 liters and that the surfacetreatment was carried out with 1.5% by weight, based on the resultingproduct, of a sodium salt of stearyl acid phosphate. The so-obtainedcomposite metal hydroxide had the following chemical composition.

    Ca.sub.0.60 Mg.sub.0.40 (OH).sub.2

The dried composite metal hydroxide was mixed with ethylene propylenediene rubber (EPDM) and other components as shown below, andmelt-kneaded and formed into a sheet with an open roll at 150° C. Thesheet was vulcanized with a press forming machine at 160° C. for 30minutes to form a sheet, and test pieces were prepared from the sheet.Table 3 shows the results.

    ______________________________________                                        EPDM                100     parts by weight                                   Zinc oxide          5       parts by weight                                   Promoter TT (tetramethyl thiuram                                                                  1.5     parts by weight                                   disulfide)                                                                    Sulfur              0.5     part by weight                                    Stearic acid        1.0     parts by weight                                   ______________________________________                                    

Comparative Example 4

The same calcium hydroxide slurry as that used in Example 1 wassurface-treated with 1% by weight, based on calcium hydroxide, oflauroyl sarcosine in the same manner as in Example 6, dried and mixedwith nylon 6, and test pieces were prepared, Table 3 shows the results.

EXAMPLE 10

A composite metal hydroxide was prepared in the same manner as inExample 7 except that the mixed aqueous solution was replaced with 12liters of a calcium chloride/magnesium chloride/ferrous chloride mixedaqueous solution (Ca²⁺ =2.0 mol/l, Mg²⁺ =0.8 mol/l, Fe²⁺ =0.1 mol/l) andthat the surface treatment was carried out in the same manner as inExample 8. The so-obtained composite metal hydroxide had the followingchemical composition.

    Ca.sub.0.50 Mg.sub.0.40 Fe.sub.0.10 (OH).sub.2

The dried composite metal hydroxide was mixed with EPDM in the samemanner as in Example 8, and test pieces were prepared. Table 3 shows theresults.

                                      TABLE 1                                     __________________________________________________________________________        Amount of                                                                     composite           Izod                                                      metal    Flamma-                                                                            Tensile                                                                             impact Appearance                                         hydroxide                                                                              bility                                                                             strength                                                                            strength                                                                             of molded                                          (part by weight)                                                                       (UL-94)                                                                            (kg · f/cm.sup.2)                                                          (kg · cm/cm)                                                                article                                        __________________________________________________________________________    Ex.1                                                                              180      V-0  185   11.0   Excellent                                      Ex.2                                                                              140      V-0  197   13.6   Excellent                                      Ex.3                                                                              140      V-0  205   12.1   Excellent                                      Ex.4                                                                              170      V-0  180   10.2   Excellent                                      Ex.5                                                                              170      V-0  187   9.3    Excellent                                      Ex.6                                                                              140      V-0  211   10.7   Excellent                                      CEx.1                                                                             170      o.o.s.                                                                             167   2.5    A                                              CEx.2                                                                             200      o.o.s                                                                              152   4.3    Excellent                                      CEx.3                                                                             150      V-0  198   11.8   Excellent                                      REx.1                                                                             --       o.o.s                                                                              280   9.6    Excellent                                      __________________________________________________________________________                         Average  Dehydration                                                   BET specific                                                                         secondary                                                                              decomposition                                       X-ray diffraction                                                                       surface area                                                                         particle temperature                                         (crystal structure)                                                                     (m.sup.2 /g)                                                                         diameter (μm)                                                                       (°C.)                                    __________________________________________________________________________    Ex.1                                                                              Ca(OH).sub.2                                                                            4.9    1.81     501                                             Ex.2                                                                              Ca(OH).sub.2, Mg(OH).sub.2                                                              5.7    1.55     520, 381                                        Ex.3                                                                              Ca(OH).sub.2, Mg(OH).sub.2                                                              7.4    1.98     523, 380                                        Ex.4                                                                              Ca(OH).sub.2,                                                                           7.7    0.84     514                                             Ex.5                                                                              Ca(OH).sub.2,                                                                           9.8    0.78     502                                             Ex.6                                                                              Mg(OH).sub.2                                                                            12.0   0.68     396                                             Ex.7                                                                              Ca(OH).sub.2,                                                                           5.5    1.94     500                                             Ex.8                                                                              Ca(OH).sub.2, Mg(OH).sub.2                                                              7.9    1.47     385, 510                                        Ex.9                                                                              Ca(OH).sub.2, Mg(OH).sub.2                                                              7.4    1.65     385, 515                                        Ex.10                                                                             Ca(OH).sub.2, Mg(OH).sub.2                                                              8.1    2.00     381, 507                                        CEx.1                                                                             Ca(OH).sub.2, Ni(OH).sub.2                                                              18.4   6.97     514, 309                                        CEx.2                                                                             Ca(OH).sub.2,                                                                           3.1    1.96     536                                             CEx.3                                                                             Mg(OH).sub.2                                                                            7.2    0.83     420                                             __________________________________________________________________________     Notes:                                                                        Ex. = Example,                                                                CEx. = Comparative Example                                                    REx. = Referential Example                                                    A: flash patterns                                                             o.o.s. = out of standard                                                 

                                      TABLE 2                                     __________________________________________________________________________        Amount of                                                                     composite           Izod                                                      metal    Flamma-                                                                            Tensile                                                                             impact Appearance                                         hydroxide                                                                              bility                                                                             strength                                                                            strength                                                                             of molded                                          (part by weight)                                                                       (UL-94)                                                                            (kg · f/cm.sup.2)                                                          (kg · cm/cm)                                                                article                                        __________________________________________________________________________    Ex.7                                                                              70       V-0  750   2.6    Excellent                                      Ex.8                                                                              60       V-0  810   2.8    Excellent                                      CEx.4                                                                             80       o.o.s                                                                              620   2.0    Excellent                                      REx.2                                                                             --       o.o.s.                                                                             630   3.2    Excellent                                      __________________________________________________________________________     Notes:                                                                        Ex. = Example,                                                                CEx. = Comparative Example                                                    REx. = Referential Example                                                    o.o.s. = out of standard                                                 

                  TABLE 3                                                         ______________________________________                                        Amount of                                                                     Composite                         Tensile                                     metal          Flamma-  Tensile   breaking                                    hydroxide      bility   strength  elongation                                  (part by weight)                                                                             (UL-94)  (kg · f/cm.sup.2)                                                              (%)                                         ______________________________________                                        Ex.9  120          V-0      102     41.0                                      Ex.10 120          V-0      105     40.0                                      CEx.4 150          o.o.s.    76     38.0                                      ______________________________________                                         Notes:                                                                        Ex. = Example,                                                                CEx. = Comparative Example                                                    REx. = Referential Example                                                    o.o.s. = out of standard                                                 

What is claimed is:
 1. A flame-retardant resin and/or rubber compositioncontaining 100 parts by weight of a resin and/or a rubber and 20 to 250parts by weight of a composite metal hydroxide of the following formula(1):

    Ca.sub.1-x M.sup.2+.sub.x (OH).sub.2                       ( 1)

wherein M is at least one metal selected from the group consisting ofMg, Mn, Fe, Co, Ni, Cu and Zn, x is in the range of 0.001≦x<0.995, andthe composite metal hydroxide is at least one of a calcium hydroxidesolid solution comprising a solution of the metal in calcium hydroxide,a metal hydroxide solid solution comprising a solution of calcium in themetal hydroxide, and a mixture thereof.
 2. A composition according toclaim 1, which further contains at least one member selected from thegroup consisting of higher fatty acids, anionic surfactants, phosphateesters, silane coupling agents, titanate coupling agents, aluminumcoupling agents, and esters of polyhydric alcohols and fatty acids.
 3. Aflame-retardant resin and/or rubber composition containing 100 parts byweight of a resin and/or a rubber and 20 to 250 parts by weight of acomposite metal hydroxide of the following formula (2):

    Ca.sub.1-x Mg.sup.2+.sub.x (OH).sub.2                      ( 2)

wherein x is in the range of 0.001≦x<0.995, and the composite metalhydroxide is at least one of a calcium hydroxide solid solutioncomprising a solution of magnesium in calcium hydroxide, a magnesiumhydroxide solid solution comprising a solution of calcium in magnesiumhydroxide, and a mixture thereof.
 4. A composition according to claim 3,which further contains at least one member selected from the groupconsisting of higher fatty acids, anionic surfactants, phosphate esters,silane coupling agents, titanate coupling agents, aluminum couplingagents, and esters of polyhydric alcohols and fatty acids.
 5. Aflame-retardant resin and/or rubber composition containing 100 parts byweight of a resin and/or a rubber and 20 to 250 parts by weight of acomposite metal hydroxide of the following formula (3):

    Ca.sub.1-x (Mg, Ni, Mn).sub.x (OH).sub.2                   ( 3)

wherein x is in the range of 0.001≦x<0.995, the composite metalhydroxide contains magnesium and at least one of Ni and Mn, and thecomposite metal hydroxide is at least one of a calcium hydroxide solidsolution comprising magnesium and at least one of Ni and Mn in calciumhydroxide, a magnesium hydroxide solid solution comprising a solution ofcalcium and at least one of Ni and Mn in magnesium hydroxide, and amixture thereof.
 6. A composition according to claim 5, which furthercontains at least one member selected from the group consisting ofhigher fatty acids, anionic surfactants, phosphate esters, silanecoupling agents, titanate coupling agents, aluminum coupling agents, andesters of polyhydric alcohols and fatty acids.